Web splicing apparatus



April 7, 7 y L. L. KQMER 3,505,148

WEB SPLICING APPARATUS Filed Dec. 29, 1966 2 Sheets-Sheet 1 INVENTOR. L.L. KOM ER A TTORNE Y8 April 7, 1970 L. L. KOMER 3,505,148

WEB SPLICING APPARATUS Filed Dec. 29, 1966 2 Sheets-Sheet 2 FIG. 6

'INVENTOR.

L. l... KOME R A TTORNEYS United States Patent 3,505,148 WEB SPLICINGAPPARATUS Louis L. Komer, Kansas City, Kans., assignor to PhillipsPetroleum Company, a corporation of Delaware Filed Dec. 29, 1966, Ser.No. 605,832 Int. Cl. B65h /04, B32b /00 US. Cl. 156361 2 Claims Thisinvention relates to an apparatus for splicing the trailing edge of aweb to the leading edge of another web.

In many industries sheets or webs of material are subjected to aprocessing step. Since large quantities of the sheet or web material areto be processed, it is necessary to handle the sheet in the mosteconomical and efficient form possible. Experience has proven the rollto be one of the most advantageous forms in which to handle largequantities of sheeting.

Since it is desirable to continuously operate a process utilizing a webor sheet, a problem is created by the necessity of having to placematerial from a new source of supply, such as a new roll, in the processafter the old roll has been expended. While it is possible to shut downthe process entirely, start a new roll of material in the process, andthen continue; a much more efiicient and economical way of switchingfrom an expended roll of sheet material to a new roll of sheet materialis to splice or bond the sheets together, or to splice or bond thesheets to a substrate to which the sheeting is being applied withoutshutting down the process. Thus, apparatus to continuously change rollsof material without effecting the continuity of the process is ofsubstantial benefit in many industrial applications.

Although the continuous method of splicing or joining the leading andtrailing edges of webs are very desirable, a problem is encountered whenthe unavoidable increased thickness resulting from the splice isconducted to further processing steps. Specifically, when the trailingedge of an expended roll of web is bonded to a substrate and the leadingedge of a new roll of web spliced to the trailing edge by bonding theleading edge over both the trailing edge and the substrate, the resultis that the leading edge is overlapping the trailing edge and theleading edge itself is exposed. Even though the leading edge is bondedto the trailing edge and substrate, the leading edge can pull up, snag,or tear when processed in additional equipment. This undesirable resultcan be eliminated if the leading edge can be bonded to the substratefirst, then the trailing edge can be subsequently bonded to the leadingedge. Thus, the leading is tucked under the trailing edge, because theleading edge has been placed between the substrate and the trailingedge. While the first method produced a leading edge that was availableto snag, tear, or pull up; the second method of splicing, in a sense,tucks the leading edge under the trailing edge so it can never snag ortear. This invention provides apparatus to achieve the placement of theleading edge under the trailing edge during the splicing of a web whichis being bonded to a substrate.

In one embodiment, this invention comprises a means to discharge undertension a web material from a first roll and to subsequently move asecond roll into the position formerly occupied by the first roll.Additionally, there are provided a means to bond a sheet of web materialto a substrate and a means to conduct a web from the discharge means tothe bonding means. In one embodiment, the means to conduct a web to thebonding means comprised a pair of rollers mounted on the ends of armswhich are mounted on a pivotal mounting bar so that the pivotal point isabout in the center of the arms but also placed to cause one side of thearms carrying the first roller to rotate downward under the influence of3,505,148 Patented Apr. 7, 1970 gravity, and thus cause the first rollerattached to that side to run on a tensioned sheet of web materialrunning from a roll to the laminating or bonding process. The leadingedge of a second roll of web material has adhesive applied thereto andis placed on the second roller on the ends of the arms which is notrunning on the first web, the arms being prevented from rotating aboutthe pivotal point by the first roller attached to the opposite ends ofthe arms running on said tensioned web.

According to the operation of the above embodiment, when the trailingedge comes off the first roll, the web tension that prevents the armsfrom rotating vanishes. Subsequently, after the tension vanishes, thearms carrying the rollers rotate about the pivotal point under theinfluence of gravity. As a result of this rotation, the second rollernot running on the tensioned web but carrying the adhesive coated end ofthe second or standby web strikes the substrate to which the web isbeing bonded. As a result of the roller striking the substrate, theleading edge of the new roll, which had been placed across the secondroller, sticks to the substrate and is carried into the laminatingprocess. The trailing edge from the expended roll is subsequentlycarried into the laminating process and the new roll is then moved bythe tension in the new web to the position of the former, but nowexpended, roll and the web tension again causes the first roller to runon the web and the second roller is withdrawn from contact with thesubstrate. Another roll is then placed on the roll supporting arms toreplace the expended roll and the end of a new web is placed over theroller not running on the web and adhesive is applied. The cycle can nowbe repeated indefinitely and the process can be continued indefinitely.Thus, according to this invention, no edges are available to snag, pullup, or tear since the leading edge of the new roll is always tu kedunder the trailing edge of the expended roll.

Accordingly, an object of this invention is to provide apparatus forsplicing the trailing edge of an expended roll of web material to theleading edge of a new roll of web material in a continuous manner sothat the primary manufacturing process need not be shut down orinterrupted during the splicing operation.

Another object of this invention is to provide apparatus for creating asplice where the leading edge of a web is tucked under the trailing edgeof a web so as to prevent the leading edge from snagging, tearing, orbeing pulled up in additional process steps.

Other objects, advantages, and features of this invention will bereadily apparent to those skilled in the art from the followingdescription, drawing, and appended claims.

FIGURE 1 is one embodiment of the invention shown during normaloperation.

FIGURES 25 indicate one complete cycle the functioning of the splicingapparatus.

FIGURE 6 is a representation of the type of splicing made by theillustrated embodiment of the invention.

With particular reference to FIGURE 1, there is indicated rollers 10 tobond a sheet of web material 11 to a substrate 12 being fed into rollers10 by rollers 13 and 14. There is additionally indicated a means 15adapted to allow a sheet of web material to discharge from a first rolland subsequently moving a second roll into the position formerlyoccupied by the expended first roll.

Since the elimination of mechanical parts, motors, springs, pulleys, andother devices is desirable, in one embodiment, means 15 was constructedso as to place the new or second, roll in the position formerly occupiedby the first roll as a result of tension in the web discharging from thesecond roll. In one embodiment of this type, a

bar was pivotally mounted and equipped with receptacles to hold a rollof web on each end of the bar. The tension in the web from the secondroll caused the bar to rotate so as to rotate the second roll into theposition formerly occupied by the first expended roll. Of course, otherembodiments of means can be used rather than the above embodiment.

Furthermore, there are indicated roller 16, roller 17, roller 18,parallel arms 19 and 19a, and pivotal mounting bar 20. With reference tothe functioning of the above apparatus, a substrate 12 is conductedthrough rollers 13 and 14 and through rollers 10 wherein a sheet of webmaterial 11 is being unroller from roll 21, conducted over roller 16 soas to place substantial tension in the web, and laminated to substrate12 by virtue of rollers 10. In one embodiment, rollers 10 comprisedheated rollers operating so as to bond web 11 to substrate 12 by virtueof the roller heat. Other devices can be used to bond web 11 tosubstrate 12 as long as the device is capable of maintaining substantialtension in the web as it unrolls from roll 21 and passes over roller 16.Specifically, the substrate and Web can be bonded together with anadhesive instead of by thermal means.

According to this invention, any substrate can be used that will bondthe selected web thereto by thermal or other means. Specifically,substrates comprising polymerized hydrocarbon, paper, metal foil, andthe like are applicable for use in this invention. Particularly,polyethylene made in accordance with the method of Hogan and Banks, U.S.Patent 2,825,721, is satisfactory.

Web 11 can comprise any material capable of being dispensed from a rolland of suflicient strength to enable substantial tension to be placed inthe Web between roll 21 and roller 16. Specifically, Web 11 can comprisepolymerized hydrocarbon, polyvinyl chloride, paper, metal foil, and thelike. In one embodiment, web 11 comprised polyethylene made according tothe method of Hogan and Banks, U.S. Patent 2,825,721, and was selectedso as to bond with a substrate made from the same material by merelyutilizing a heated roller 10.

As has been previously mentioned, if the substrate and web are notcapable of being thermally bonded, a glue or adhesive can be resortedto, as it is fully within the scope of this invention to bond the web tothe substrate in any manner whatsoever.

With additional reference to FIGURE 1, there is indicated arms 19 and19a holding rollers 17 and 18. Since FIGURE 1 is an elevation view, arm19a appears directly behind arm 19 but cannot be seen. Arms 19 and 1911are mounted on a pivotal mounting bar 20. According to this invention,arms 19 and 19a retaining rollers 17 and 18 are mounted on a pivotalmounting bar 20 so as to naturally rotate rollers 17 and 18 in aclock-wise direction around pivotal bar 20, as shown in FIGURE 1position. The rotation function can be accomplished by utilizing agravitational influence to induce a clockwise moment. Alternatively, aspring-biased or mechanically induced clock-Wise moment can be used. Inone embodiment, roller 17 was slightly heavier than roller 18, therebygenerating a clock-wise gravitational moment about pivotal mounting bar20 since the rollers are equidistant from pivotal mounting bar 20. Ascan be seen, the clock-wise torque around pivotal mounting bar 20created by gravity or mechanical means causes roller 17 to run on thatportion of web 11 coming oif roll 21 and running over roller 16. Statedanother Way, the tension in web 11 between roll 21 and roller 16counterbalances or arrests the induced rotation of arm 19, therebypreventing rotation of arms 19 and 19a and rollers 17 and 18.

According to the operation of this invention, when roll 21 is expended,the tension in web 11 between roll 21 and roller 16 vanishes. As aresult of arms 19' and 19a tending to rotate in a clock-Wise direction,roller 18 is 4 brought in contact with moving substrate 12. As will benoted in FIGURE 1, the leading edge 23 of web 22 coming off roll 24 hasbeen placed over roller 18 and adhesive thereto. As roller 18 contactsmoving substrate 12 as a result of the rotation of arms 19 and 190, theadhesive on leading edge 23 bonds to moving substrate 12. As a result ofleading edge 23 being bonded to moving substrate 12, web 22 is thenpulled through rollers 10 and caused to ride over roller 16. As web 22is pulled through rollers 10, the tension in Web 22 is increased and themeans adapted to move a second roll into the position formerly occupiedby an expended roll is caused to rotate by the tension in web 22. Thisrotation subsequently places roll 24 as was roll 21 formerly and thetension in the web again restricts the rotation of arms 19 and 19a, androller 18' is removed from contact with the substrate. A new roll cannow be placed in the position formerly occupied by roll 21 and drapedover roller 18 and adhesive applied thereto. Thus, the cycle can berepeated indefinitely and the system need never be shut down for websplicing. Means 15 can comprise any means adapted to allow a roll ofmaterial to discharge from a first roll with suflicient tension in theweb and then subsequently move a second roll into the same position asthe original roll so as to efiect a similar amount of tension as did thefirst roll. This tension will thereby raise roller 17 so as to ride onthe moving Web and lower roller 18 so as to permit the leading edge of anew roll to be placed thereon. In one embodiment, means 15' comprised abar adapted to mount rollers on each end and pivoted for rotation in thecenter. In the embodiment described above, the rotation which placedroll 24 in the position of roll 21 after it was expended was merely thetension force of the substrate as it was fed into the bonding operationpulling at roll 24. If a bar such as in the above embodiment is used, amechanical or spring means can be used to rotate the bar withoutdeparing from the scope of this invention. Additionally, other devicescan be employed that would place the new roll in the position of the oldroll and thereby create sufiieient tension to arrest the rotation ofarms 19 and 19a and thereby function according to this invention.

The precise functioning of the apparatus will now be described in astep-by-step manner with reference to FIG- URES 2P5.

With reference to FIGURE 2, there is indicated the same embodiment as isshown in FIGURE 1 except that the process has expended all but the verylast portions of roll 21.

In FIGURE 3 there is indicated the rotation feature of the apparatus.As'will be noted in FIGURE 3, the trailing edge 25 of the substrate 11that was used to comprise roll 21 has fallen away from means 15. As willbe noted, when trailing edge 25 falls from means 15, the tension in theweb between roll 21 and roller 16 vanishes and the clock-Wise rotationaltendency of arms 19 and 19a is no longer impeded. Thus, roller 17 fallsand roller 18 rises. As roller 18 rises, it contacts moving substrate12. As was previously noted, the leading edge 23 of substrate 22 hasbeen draped over roller 18 and adhesive applied thereto; thus, as roller18 strikes substrate 12, leading edge 23 is bonded to substrate 12 andthe movement of substrate 12 rolls the entire edge 23 onto substrate 12.During the rotation function the substrate 12 is, of course, continuallymoving. Thus, as leading edge 23 is bonded to substrate 12, trailingedge 25 is still free.

As illustrated in FIGURE 4, leading edge 23 has been bonded to substrate12 and the motion of substrate 12 has pulled the leading edge 23 intorollers 10, thereby causing substrate 22 to ride over roller 16 andcause substantial tension in web 22. In the embodiment beingillustrated, the tension in web 22 from roll 24 causes the bar in means15 to rotate so as to place roll 24 in the same position as was formerlyoccupied by roll 21.

It will be further noted in FIGURE 4 that, although I web 22 has beendrawn taut by the action of rollers and substrate 12, trailing edge 25of the expanded roll of substrate is still free and will be subsequentlybonded to substrate 22 by the action of rollers 10.

With reference to FIGURE 5, there is indicated the position of the barin one embodiment of means 15. As will be noted, the tension in web 22has caused roll 24 to swing to a position similar to that in which roll21 formerly resided. The tension in web 22 and the position of roll 24have elevated roller 17 against the aforementioned torque and havepositioned roller 17 in the same manner as shown in FIGURE 1.Corresponding to the upward movement of the roller 17 against thetorque, roller 18 is moved downward and is no longer in contact withsubstrate 12. Thus, according to the operation of this invention, athird roll 26 can now be placed where roll 21 formerly resided, and theleading edge 28 of web 27 being removed from roll 26 is draped overroller 18 and adhesive applied thereto. It will be readily understoodthat the embodiment illustrated in FIGURE 5 is precisely the same asthat illustrated in FIGURE 1. Thus, one complete cycle of apparatusoperation has been illustrated. Therefore, according to this invention,the apparatus will continue to cycle and the lamination or bondingprocess need never be terminated on account of the necessity to splicewebs of material together.

FIGURE 6 is a representation of the type of splice made by theembodiment illustrated. As has been previously mentioned, this apparatusachieves the remarkable and desirable result of always tucking theleading edge of a new roll of material under the trailing edge of anexpended roll of material so as to prevent the leading edge fromsnagging, tearing, or being pulled up in additional processingequipment. Examples of hazards that can pull up, tear, or snag a leadingedge, if exposed, are thickness gauges, edge guides, rollers, and airblasts used for curing and drying. This desirable objective of neverproducing a splice where the leading edge is exposed to the possibilityof tearing, snagging, or being pulled up is achieved through the use ofthis apparatus regardless of the number of cycles or rolls that areused.

As will be noted with reference to FIGURE 3, leading edge 23 hadadhesive applied to the side that will contact substrate 12. Roller 18then rolled leading edge 23 backwards and a fold was made as the webcontinued into the rollers. With particular reference to FIGURE 6, thereis indicated the particular manner in which leading edge 23 has beenbounded to substrate 12. There is additionally indicated a fold 29caused by the bonded edge 23 being rolled into the rollers. It is to benoted that the trailing edge 25 of substrate 11 from expended roll 21 isbonded to substrate 22 behind the leading edge 23 and fold 29, therebyavoiding entirely the problem of the leading edge snagging or pulling upduring additional processing. The pulling up or tearing problem isadditionally eliminated noting the smooth transition area 30 between thebonded substrate and the spliced area. This smooth transition will notresult in tearing or pulling up of the leading edge as would bonding theleading edge on the outside of the trailing edge.

This invention is thus applicable to splicing the leading edge of a webmaterial to the trailing edge of another material by tucking the leadingedge under the trailing edge and bonding both webs to a substrate so asto produce a splice where the trailing edge is not exposed to tears,snags, or being pulled up.

What is claimed is:

1. Apparatus for bonding web material to a substrate comprising, incombination, a pair of heated rollers adapted to receive a movingsubstrate; a pivoted carriage adapted to receive a roll of web materialat each end thereof; means for guiding web material from the end of saidcarriage adjacent said rollers onto one of said rollers, whereby the webis bonded to the substrate; means for guiding web material from the endof said carriage remote from said rollers to a position adjacent saidsubstrate ahead of said rollers; and means for bonding thelast-mentioned web to said substrate when the first roll of web materialis exhausted, whereby the tension of said last-mentioned web pivots saidcarriage and moves said remote end to said position adjacent saidrollers.

2. The apparatus of claim 1 wherein said carriage means comprises twoweb roll spindles placed on each end of a pivotally mounted bar adaptedto rotate about the pivotal mounting and place the second roll in theposition of the first roll due to tension in the web discharging fromthe second roll, wherein said means for guiding web material to saidrollers comprises:

(a) a plurality of arms spaced apart and pivotally mounted on a bar soas to position a portion of the arms on both sides of the bar, saidpivotal mounting also inducing a rotation to said arms;

(b) a roller adapted to conduct under suitable tension a sheet ofwebbing unrolliing from the first roll over said roller and to saidmeans for bonding the web to a substrate, said web thereby being bondedor 1aminated to the substrate;

(c) first roller attached between two of said plurality of arms on oneside of said mounting bar, said first roller and arms being preventedfrom rotating by said roller running on the web which runs undersuitable tension from the first roll of web material to said singleroller; and

(d) second roller attached between the remaining side of said arms andadapted to permit the adhesive covered leading edge of the second rollof web material previously placed over said second roller to be bondedto a substrate, said bonding action occurring when the trailing edge ofsaid web material comes off the first roll, thereby eliminating thetension required to prevent first roller from rotating, said eliminationof web tension causing first roller and arms to rotate, thereby movingsaid second roller to a position in contact with the substrate so as tobond the leading edge of said second web to said substrate, said meansto move a new roll into the position formerly occupied by an expendedroll, then moving said second roll into the position of the expendedfirst roll, thereby again returning first roller to its originalposition and preventing its rotation due to the tension in the web.

References Cited UNITED STATES PATENTS 2,354,120 7/1944 Haren 156361BENJAMIN A. BOROHELT, Primary Examiner S. C. BENTLEY, Assistant ExaminerUS. Cl. X.R.

1. APPARATUS FOR BONDING WEB MATERIAL TO A SUBSTRATE COMPRISING, INCOMBINATION, A PAIR OF HEATED ROLLERS ADAPTED TO RECEIVE A MOVINGSUBSTRATE; A PIVOTED CARRIAGE ADAPTED TO RECEIVE A ROLL OF WEB MATERIALAT EACH END THEREOF; MEANS FOR GUIDING WEB MATERIAL FROM THE END OF SAIDCARRIAGE ADJACENT SAID ROLLERS ONTO ONE OF SAID ROLLERS, WHEREBY THE WEBIS BONDED TO THE SUBSTRATE; MEANS FOR GUIDING WEB MATERIAL FROM THE ENDOF SAID CARRIAGE RE-